Means for forming structures of complex configuration

ABSTRACT

This invention is a method and means for forming structures of complex configuration from cementitious materials wherein the faces of the complex configuration are defined by a preshaped form liner against which the cementitious material is cast and then is permanently adhered when the structure cures. A network of steel reinforcing rod or mesh and, in some instances, a structural steel nosing are attached to and supported from the form liner for steel reinforced concrete construction.

1.1110 tate ate 1 [19] 111] 3,844,073 Peletz Oct. 29, 1974 [54] MEANS FOR FORNHNG STRUCTURES OF 3,393,614 7/1968 Peletz 404/4 COMPLEX CO U N 3,631,545 7/1972 Orndorff 52/169 [76] lnventor: Harold Peletz, c/o Santa Rosa Cast FOREIGN PATENTS OR APPLICATIONS Products, Inc., 471 W. College 409,349 10/1966 Switzerland 52/ 169 1 Ave., Santa Rosa, Calif, 95401 98,936 5/1940 Sweden 52/169 607,223 8/1948 Great Britain.. 404/4 Filed: l 7, 1973 779,829 4/1935 France 404/2 [21] Appl. No.: 395,210 E J h E M h rzmary xammero n urtag Related Applicauon Data Assistant ExaminerHenry Raduazo [63] Continuation of Ser. No. 225,992, Feb. 14, 1972,

abandoned. 5 7 ABSTRACT 52 us. (:1 52/20 52/102 52/169 This is a methd and means fmming 40422 4041/8 structures of complex configuration from cementitious [51] Int. Cl E02; 29 materials wherein the faces of the complex configura- 58 Field 0152 211211IIIIIIIIIII527102, 20 21 169; are defined by a Preshaped fOYm line against which the cementitious material is cast and then is 404,8 4/17211 172'19 permanently adhered when the structure cures. A net- [56] References Cmd work of steel reinforcing rod or mesh and, in some instances, a structural steel nosing are attached to and UNITED STATES PATENTS supported from the form liner for steel reinforced conl,034,504 8/1912 Pindell 404/8 crete construction. 1,281,405 10/1918 Marquess 52/20 2,558,580 6/1951 Pomykala 52/20 4 Claims, 12 Drawing Figures MEANS FOR FORMING STRUCTURES OF COMPLEX CONFIGURATION This is a continuation of application Ser. No. 225,992, filed Feb. 14, 1972, and now abandoned and pertains to an invention which relates to methods and means for casting structures of complex configuration and more particularly relates to the casting of steel reinforced concrete structures of complex configuration.

The method and means are particularly suited to casting reinforced concrete drainage structures in remote field locations in conjunction with presently used forming methods for curbing and the like.

A principal object of the invention is to provide a method and means for casting cementitious structures of complex configuration in remote locations without complex molding equipment.

Another object of this invention is to provide a form liner assembly for defining the complex configuration to be cast and for carrying the reinforcing steel requisite for structural strength in reinforced concrete design.

Other objects and advantages of the invention will become apparent from a consideration of the following description of the embodiments of the invention shown in the accompanying drawings wherein FIG. 1 is a perspective view of the form liner assembly of this invention used for casting a typical curb hood drainage structure;

FIG. 2 is a top view of the form liner assembly of FIG. I with the reinforcing rods omitted for clarity of illustration;

FIG. 3 is a cross-sectional view of the form liner assembly of FIGS. 1 and 2 taken at line 33 of FIG. 2 and showing it in place for field casting;

FIG. 4 is a perspective view of a form liner assembly for casting a typical curb inlet structure;

FIG. 5 is a perspective view of a form liner assembly for casting a typical curb gallery;

FIG. 6 shows two detailed sectional views of means for attaching the reinforcing network to the preshaped form liner of such assemblies;

FIG. 7 shows a third means for attaching the reinforcing network to the preshaped form liner of such assemblies;

FIG. 8 is a perspective view of an alternative form liner assembly for casting a curb hood;

FIG. 9 is a top view of the form liner assembly of FIG. 8 in casting emplacement against a typical curb faceboard and with portions of the reinforcing network omitted for clarity of illustration;

FIG. 10 is a sectional view of the form liner assembly of FIG. 8 taken along line 10-10 of FIG. 11;

FIG. 11 is a front elevational view of the form liner assembly of FIG. 8; and

FIG. I2 is a sectional view of the form liner assembly of FIG. 8 taken along line l2l2 of FIG. 11.

The method of this invention comprises the steps of initially defining the faces of the complex configuration to be cast with a preshaped form liner; casting cementitious material, such as concrete, against that preshaped form liner and other forms as required to define the complete structure; and then curing the cementitious material in adherence with the liner to form a finished monolithic structure with which the preshaped form liner remains intact. It is not stripped as is the case of the other forms which may be used to define the complete structure. If the structure is to be steel reinforced, the network of steel reinforcing mesh or rod is integrally attached to the preshaped form liner and supported from it in a composite form liner assembly. The assembly is placed in the field and concrete is cast against the preshaped form liner and around the network of reinforcing steel to complete the structure. The reinforcing steel network aids in anchoring the preshaped form liner to the cast concrete.

The drawings illustrate several specific embodiments of the invention used for field casting of reinforced concrete drainage structures. The same type of form liner assembly and casting method can be employed for other structures having complex or irregular configurations. The drainage structures are shown only by way of example.

FIGS. 1-3 illustrate a form liner assembly for casting a typical curb hood that conducts surface drainage to a storm sewer running below it. The assembly comprises preshaped form liner 1 against the rear surface 2 of which cementitious material, such as concrete is cast. The front surfaces 3 of the form liner remain exposed after casting and define the water receiving orifice of the hood. Any durable material such as metal, molded fiberglass or other plastic is suitable for the preshaped form liner.

In the assembly of FIGS. 1-3 a metallic nosing 4 of galvanized steel spans the top of the water receiving orifice of the assembly for supporting externally applied bending loads. A network 11 of steel reinforcing mesh or rods affixed to the preshaped form liner 1 completes the assembly. As is shown in FIG. 3 the network can be mounted directly from the preshaped form liner 1 as at 23 or from anchors 5 which by means of nuts 6, 7 secure the nosing 4 to the form liner 1. Each anchor has a straight or hooked anchor end 8 that embeds in the cast concrete, with the reinforcing steel, to anchor the nosing and form liner.

The form liner assembly of FIGS. 1-3 is placed in the field, for example, nailed as at 16 to a typical face board 13 used to form curbs with the edges 14 of the assembly aligned with the curb face in abutment with face board 13 as in FIG. 3. A strippable form 15 placed behind the form liner assembly at whatever distance is required in the particular design completes the molding cavity. Concrete is then poured into the molding cavity defined by face board 13, form liner 1 and strippable form 15 to cast the curb hood at the same time as the adjacent curbing, for example, is cast. The concrete cures in adherence with the network of reinforcing steel and the preshaped form liner 1 which remains in place to define the orifice of the hood. Anchors 5 and the reinforcing steel network 11 assist in integrating the entire structure.

FIGS. 6 and 7 show alternative means for attaching the network of reinforcing steel to the preshaped form liner 1. Those in FIG. 6 comprise additional fiberglass or other plastic material of which the preshaped form liner itself is made. molded as at 22 or 23 over an L shaped 20 or T-shaped 21 end of the reinforcing steel ll. FIG. 7 illustrates another means for attaching a reinforcing steel network 11 to the preshaped form liner 1 with pieces of plastic tubing 25 laminated to the preshaped form liner into which L-shaped ends 20 of the reinforcing steel network are press fit.

FIG. 4 is another design of form liner assembly for casting a curb drainage inlet structure with a manhole overlying the water receiving orifice. The preshaped form liner 101 includes an upwardly rising cylindrical portion 103 which defines manhole 102 and a cover retaining seat 104. Galvanized steel nosing 107 with nail holes 116 spans the drainage orifice defined by sidewalls 110 and 111. A network of reinforcing mesh 108 attaches to and overlies the rear faces of the preshaped form liner spaced from it an appropriate distance for the concrete aggregate size contemplated.

FIG. illustrates a form liner assembly for casting gallery type drainage structures. The assembly 120 comprises preshaped form liner 121 having a curb inlet surface 124 which generally opens in a taper to outlet 125 that normally commuicates with the orifice of an adjacent hood or curb inlet such as illustrated in FIGS. 1 or 4. A metallic nosing 122 with nail holes 126 overlies the water receiving orifice of the gallery for structural strength and a network of reinforcing mesh 123 attaches to the preshaped form liner 121 and is spaced from its rear surfaces.

FIG. 8 illustrates a form liner assembly for another design of curb hood which does not employ a metallic nosing. This form liner assembly 130 includes form liner 131, the front faces 132 of which define a water receiving orifice that empties through throat 133 to a storm sewer running below the structure. A network 134 of steel reinforcing mesh affixes to the rear faces 135 of the form liner 131 with attachment means of the type in FIG. 7, for example, to complete the assembly.

The form liner assembly of FIGS. 8-12 is placed in the field simply by tacking it as at 138 to the curb face board 136, for example, as illustrated in hidden lines in FIG. 9. FIG. 8 in hidden lines illustrates the orientation of the form liner assembly with respect to the ultimately cast concrete curb 137. The curb is cast in depth over the orifice of the form liner and may be provided with separate steel reinforcing to span the orifice with adequate structural strength in bending.

The embodiments described herein are for illustrative purposes only. Modifications to the structures and methods will be apparent to those skilled in the art which are within the scope of the invention in the following claims.

I claim:

1. A form assembly for in-the-field casting of reinforced concrete drainage structures having an external face portion constituting a reentrant concavity of complex geometrical configuration in such structure, including an integral preshaped form liner member of generally concavo-convex configuration corresponding to such reentrant concavity of complex geometrical configuration in such structure, said integral preshaped form liner member having a front surface and a rear surface, said front surface forming such external face portion of the completed structure, a network of rod-like reinforcing members of generally concavo-convex overall configuration adapted to substantially encompass said rear surface of said integral preshaped form liner member, selected ones of said rod-like reinforcing members having end portions of generally hooked configuration,

means on said rear surface of said integral preshaped form liner member for receiving and holding captive said hooked end portions of such rod-like reinforcing members to mount said network of reinforcing members on said rear surface of said integral preshaped form liner member in generally spaced relationship therewith, an elongate reinforcing nosing member of substantially L-shaped cross-section mounted on said integral preshaped form liner member adjacent an edge thereof to reinforce such edge of said form liner member against bending forces, and

mounting means forming a part of said elongate reinforcing nosing member for attaching thereto ancillary form members of relatively simple geometrical configuration to complete a form assembly of desired overall configuration.

2. A form assembly for in-the-field casting of reinforced concrete draingage structures in accordance with claim 1, wherein said front surface of said integral preshaped form liner member comprises a roadway curb opening for conducting surface drainage from such roadway into an associated storm sewer therebelow, and said elongate reinforcing nosing member is mounted on the edge of said integral preshaped form liner member above such roadway curb opening.

3. A form assembly for in-the-field casting of reinforced concrete drainage structures in accordance with claim 2, said integral preshaped form liner member including an upwardly-rising cylindrical portion adjacent said elongate reinforcing nosing member and defining a circular manhole opening through said integral preshaped form liner member.

4. A form assembly for in-the-field casting of reinforced concrete drainage structures in accordance with claim 1, wherein said front surface of said integral preshaped form liner member comprises an elongate tapered opening of a gallery drainage structure for conducting roadway surface drainage therealong, and said elongate reinforcing nosing member is mounted on the edge of said integral preshaped form liner member above such roadway curb opening. 

1. A form assembly for in-the-field casting of reinforced concrete drainage structures having an external face portion constituting a reentrant concavity of complex geometrical configuration in such structure, including an integral preshaped form liner member of generally concavoconvex configuration corresponding to such reentrant concavity of complex geometrical configuration in such structure, said integral preshaped form liner member having a front surface and a rear surface, said front surface forming such external face portion of the completed structure, a network of rod-like reinforcing members of generally concavoconvex overall configuration adapted to substantially encompass said rear surface of said integral preshaped form liner member, selected ones of said rod-like reinforcing members having end portions of generally hooked configuration, means on said rear surface of said integral preshaped form liner member for receiving and holding captive said hooked end portions of such rod-like reinforcing members to mount said network of reinforcing members on said rear surface of said integral preshaped form liner member in generally spaced relationship therewith, an elongate reinforcing nosing member of substantially L-shaped cross-section mounted on said integral preshaped form liner member adjacent an edge thereof to reinforce such edge of said form liner member against bending forces, and mounting means forming a part of said elongate reinforcing nosing member for attaching thereto ancillary form members of relatively simple geometrical configuration to complete a form assembly of desired overall configuration.
 2. A form assembly for in-the-field casting of reinforced concrete draingage structures in accordance with claim 1, wherein said front surface of said integral presHaped form liner member comprises a roadway curb opening for conducting surface drainage from such roadway into an associated storm sewer therebelow, and said elongate reinforcing nosing member is mounted on the edge of said integral preshaped form liner member above such roadway curb opening.
 3. A form assembly for in-the-field casting of reinforced concrete drainage structures in accordance with claim 2, said integral preshaped form liner member including an upwardly-rising cylindrical portion adjacent said elongate reinforcing nosing member and defining a circular manhole opening through said integral preshaped form liner member.
 4. A form assembly for in-the-field casting of reinforced concrete drainage structures in accordance with claim 1, wherein said front surface of said integral preshaped form liner member comprises an elongate tapered opening of a gallery drainage structure for conducting roadway surface drainage therealong, and said elongate reinforcing nosing member is mounted on the edge of said integral preshaped form liner member above such roadway curb opening. 